Folded sheets of material for use as a structural member and assembly thereof

ABSTRACT

Disclosed herein are folded sheets of material for use as a structural member and assembly thereof. According to an aspect, a sheet of material defines one or more tabs, slots, and a plurality of fold lines. The fold lines are spaced such that folding the sheet along the fold lines places the slots in substantial alignment for receiving the at least one tab such that a structural member having a web formed in an interior thereof is formed.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. provisional patentapplication No. 61/382,663, filed Sep. 14, 2010, the content of which ishereby incorporated herein by reference in its entirety.

TECHNICAL FIELD

The present disclosure relates to structural members. More particularly,the present disclosure relates to structural members formed from afolded sheet of material.

BACKGROUND

Structural members such as support legs, horizontal supports, andconnectors for support legs and horizontal supports, can be formedemploying processes such as extruding, metal forming, molding, andcasting. These processes typically require specialized machinery andoperators or craftsman having specialized skills. Accordingly, thestructural members are often produced and assembled at a first locationand transported to an end user at another location.

Transporting structural members and assemblies can result in packagingor stacking a plurality of the structural members together. It istypically desired to maximize the number of structural members in agiven volumetric space to minimize costs of transporting the structuralmembers. However, the produced and assembled structural members oftenare of a shape that includes cavities formed therein or that result inthe structural members being spaced apart when packaged or stacked.Accordingly, the volumetric space employed to transport the structuralmembers can include a significant amount of empty space which increasesthe volumetric space required to transport the structural members andthus increases costs of transporting the structural members.

For at least the aforementioned reasons, it is desirable to provideimproved materials for transportation and assembly.

SUMMARY

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This Summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tobe used to limit the scope of the claimed subject matter.

Disclosed herein are folded sheets of material for use as a structuralmember and assembly thereof. According to an aspect, improved materialsare disclosed herein for transportation and assembly. For example, at anend user, a folded sheet of material as disclosed herein may beassembled to form a desired structure.

According to an aspect, a sheet of material defines one or more tabs,slots, and a plurality of fold lines. The fold lines are spaced suchthat folding the sheet along the fold lines places the slots insubstantial alignment for receiving the at least one tab such that astructural member having a web formed in an interior thereof is formed.

According to another aspect, a sheet of material defines a plurality offold lines and attachment portions, wherein the fold lines are spacedsuch that folding the sheet along the fold lines places the attachmentportions in substantial alignment such that a structural member having aweb formed in an interior thereof is formed. Aligned attachment portionsmay include portions that are adhered together. Further, alignedattachment portions may include a tab that may be received into a slotfor attachment.

According to another aspect, a framework of interconnected structuralmembers may be formed from sheets of material. The framework includes anelongate member having a first end and a second end and a web formed inan interior thereof. The elongate member is formed from a first sheet ofmaterial defining one or more tabs, a pair of slots, and a plurality offold lines. The fold lines are spaced such that folding the sheet alongthe fold lines places the slots in substantial alignment for receivingthe tabs such that the elongate member having the web formed in theinterior is formed. The framework also includes a connector including atleast a first male end and a second male end. The male ends may bereceived in either the first end or the second end of the elongatemember to selectively join together a plurality of the elongate members.The connector is formed from a second sheet of material defining aplurality of fingers. The second sheet defines a plurality of foldlines. Further, folding the second sheet along the fold lines configuresthe fingers to form the first male end and the second male end of theconnector. Alternately, the connector is formed from one or more sheetsof material defining a plurality of fingers wherein the one or moresheets defines a plurality of fold lines, wherein folding the one ormore sheets of material along the fold lines configures the fingers toform a first male end, a second male end and a third male end of theconnector.

According to yet another aspect, a sheet of material for forming aconnector to assemble together a plurality of structural members isdisclosed. The sheet defines a plurality of fingers and a plurality offold lines. Folding the sheet along the fold lines configures thefingers to form a plurality of male ends for receipt in an opening of astructural member to selectively assemble together a plurality of thestructural members.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description ofpreferred embodiments, is better understood when read in conjunctionwith the appended drawings. For the purposes of illustration, there isshown in the drawings exemplary embodiments; however, the presentlydisclosed subject matter is not limited to the specific methods andinstrumentalities disclosed. In the drawings:

FIG. 1A is a perspective view of an elongate structural member accordingto an embodiment of the present subject matter;

FIG. 1B(i) is an end elevational view of the elongate structural memberof FIG. 1 showing an internal web according to an embodiment of thepresent subject matter;

FIG. 1B(ii) is another end elevational view of the elongate structuralmember of FIG. 1 showing an internal web according to an embodiment ofthe present subject matter;

FIG. 1C is a top plan view of a sheet of material from which theelongate structural member of FIGS. 1A and 1B(i) is formed according toan embodiment of the presently disclosed subject matter;

FIG. 1D is a top plan view of another embodiment of a sheet of materialfrom which the elongate structural member of FIGS. 1A and 1B(i) isformed according to an embodiment of the present subject matter;

FIGS. 1E-1J are perspective views of the sheet of material of FIG. 1Cshowing steps of folding the sheet of material to assemble the elongatestructural member of FIGS. 1A and 1B(i) according to an embodiment ofthe present subject matter;

FIG. 2A is a top plan view of a sheet of material from which aninety-degree connector is formed according to an embodiment of thepresent subject matter;

FIGS. 2B-2D are perspective views of the sheet of material of FIG. 2Ashowing steps of folding the sheet of material to assemble theninety-degree connector according to an embodiment of the presentsubject matter;

FIG. 2E is a perspective view of the ninety-degree connector formed fromthe sheet of material of FIG. 2A according to an embodiment of thepresent subject matter;

FIGS. 2F-2I are perspective views of the ninety-degree connector of FIG.2E being employed to join together two of the elongate structuralmembers of FIGS. 1A and 1B(i) according to an embodiment of the presentsubject matter;

FIG. 3A is a top plan view of a sheet of material from which aT-connector is formed according to an embodiment of the present subjectmatter;

FIGS. 3B and 3C are perspective views of the sheet of material of FIG.3A showing example steps of folding the sheet of material to form theT-connector according to an embodiment of the present subject matter;

FIG. 3D-3G are perspective views of the T-connector of FIG. 3C beingemployed to join together three of the elongate structural members ofFIGS. 1A and 1B(i) according to an embodiment of the present subjectmatter;

FIG. 4A is a top plan view of sheets of material from which a cornerconnector is formed according to an embodiment of the present subjectmatter;

FIGS. 4B-4J are perspective views of the sheets of material of FIG. 4Ashowing steps of interconnecting and folding the sheets of material ofFIG. 4A to form the corner connector according to an embodiment of thepresent subject matter;

FIGS. 4K-4N are perspective views of the corner connector of FIG. 4Ibeing employed to join together three of the elongate structural membersof FIGS. 1A and 1B according to an embodiment of the present subjectmatter; and

FIG. 5 is a top plan view of a sheet of material from which a trussconnector may be formed according to an embodiment of the presentsubject matter.

DETAILED DESCRIPTION

The presently disclosed subject matter is described with specificity tomeet statutory requirements. However, the description itself is notintended to limit the scope of this patent. Rather, the inventors havecontemplated that the claimed subject matter might also be embodied inother ways, to include different steps or elements similar to the onesdescribed in this document, in conjunction with other present or futuretechnologies. Moreover, although the term “step” may be used herein toconnote different aspects of methods employed, the term should not beinterpreted as implying any particular order among or between varioussteps herein disclosed unless and except when the order of individualsteps is explicitly described.

In one aspect, the present application discloses a framework ofinterconnected structural members formed from sheets of material. Theframework comprises an elongate member having a first end and a secondend and a web formed in an interior thereof, the elongate member formedfrom a first sheet of material including at least one tab formed thereinand a pair of slots, the first sheet having a plurality of fold lines,wherein folding the first sheet along the fold lines places the slots insubstantial alignment for receiving the tab to form the elongatestructural member; and a connector having at least a first male end anda second male end, the male ends received in one of the first end andthe second end of the elongate member to selectively join together aplurality of the elongate members, the connector formed from a secondsheet of material including a plurality of fingers, the second sheethaving a plurality of fold lines, wherein folding the second sheet alongthe fold lines configures the fingers to form the first male end and thesecond male end of the connector.

In another aspect, the present application discloses a framework ofinterconnected structural members formed from sheets of material. Theframework may include an elongate member having a first end and a secondend and a web formed in an interior thereof. The elongate member may beformed from a first sheet of material defining a plurality of attachmentportions and a plurality of fold lines. The fold lines may be spacedsuch that folding the sheet along the fold lines places the attachmentportions in substantial alignment for attachment such that a structuralmember having a web formed in an interior thereof is formed. Theattachment portions may be attached together by a suitable adhesive, ora tab and slot as disclosed herein. The framework may include aconnector having at least a first male end and a second male end. Themale ends may be received in one of the first end and the second end ofthe elongate member to selectively join together a plurality of theelongate members. The connector may be formed from at least one secondsheet of material defining a plurality of fingers. The second sheet maydefine a plurality of fold lines. Folding the second sheet along thefold lines can configure the fingers to form the first male end and thesecond male end of the connector.

In an embodiment, structural members of the presently disclosed subjectmatter are interconnected to form any one or more of a chair, a table, adesk, a trunk, a bench, a stool, a cot, a shelf, a shipping pallet, ashipping crate, a load-carrying platform, a raised floor, a display, anda shelter. In one variation, such structures are used as children'sfurniture or play structures, in another variation, such structures areused for ‘full size’ or adult furniture or structures. In anotherembodiment, the elongate members can be used in place of bricks, such aswhen bricks are used to support shelves, as in bookshelves. Elongatemembers disclosed herein can also be used as building blocks inchildren's play structures. In an embodiment, structural membersdisclosed herein are not components of a pallet.

In another aspect, the present application discloses a sheet of materialfor forming an elongate structural member comprising a sheet of materialincluding at least one tab formed therein and a pair of slots, the sheethaving a plurality of fold lines, wherein folding the sheet along thefold lines places the slots in substantial alignment for receiving thetab and forms an elongate structural member having a web formed in aninterior thereof. In one embodiment, the sheet comprises an end and atleast one tab is defined at the end of the sheet. In another embodiment,the tab is defined along one of the fold lines.

According to another aspect, the present application discloses a sheetof material for forming an elongate structural member. The sheet ofmaterial may define a plurality of fold lines and adhesive locations.The fold lines may be spaced such that folding the sheet along the foldlines places the adhesive locations in substantial alignment forattachment such that a structural member having a web formed in aninterior thereof is formed.

In one embodiment, the elongate member has a cross-sectional area thatis a parallelogram. In another embodiment, the elongate member has across-sectional area that is a trapezoid.

In another embodiment, the elongate member has a cross-sectional areathat is a rhombus. In yet another embodiment, the elongate member has asubstantially rectangular cross-sectional area. In another embodiment,the elongate member has a substantially square cross-sectional area.

In one embodiment of any disclosed aspect, the cross-sectional area ofthe web formed in the interior of the elongate member does not have anM, W, or V shape. In another embodiment, the cross-sectional area of theweb does not have an M, N, V, W, Y, or Z shape. In one variation, thecross-sectional area of the web generally has an X-shape.

In one variation, the sheet of material for forming an elongatestructural member comprises at least about 6 panel segments, orsections, and 5 fold lines, wherein the panel segments and fold linesare identified by means of imprinting said sheet with perforations, ink,pencil, stickers or other such indicative means, such as a set ofwritten instructions. In another variation, the sheet of material forforming an elongate structural member comprises at least about 8 panelsegments and 7 fold lines. In yet another variation, the sheet ofmaterial for forming an elongate structural member comprises at leastabout 9 panel segments and 8 fold lines. In a further variation, thesheet of material comprises at least about 10 panel segments and 9 foldlines. In still a further variation, the sheet of material comprises atleast about 11 panel segments and 10 fold lines.

In another aspect, the present application discloses a sheet of materialfor forming a connector to join together a plurality of structuralmembers comprises a sheet of material including a plurality of fingers,the sheet having a plurality of fold lines, wherein folding the sheetalong the fold lines configures the fingers to form a plurality of maleends for receipt in an opening of a structural member to selectivelyjoin together a plurality of the structural members. In one embodiment,folding the sheet of material along the fold lines aligns two or morefingers in a substantially parallel and adjacent way to one another toform a male end. In one variation, these substantially parallel andadjacent fingers can be adhered to one another.

In one embodiment, the connector formed from a sheet of material asdisclosed herein comprises two male ends disposed 180° apart, whereinone male end extends in the opposite direction from a second male end.In another embodiment, the connector formed from a sheet of material asdisclosed herein comprises two male ends disposed between about 90° and180° apart, such as in a ‘truss’ connector. Alternately, the trussconnector comprises two male ends disposed about 135° apart. In yetanother embodiment, the connector formed from a sheet of material asdisclosed herein comprises two male ends disposed 90° apart (e.g. in an“L” shape). In yet another embodiment, the connector formed from a sheetof material as disclosed herein comprises three male ends disposed in a“T” shape, wherein one male end extends in a direction opposite to asecond male end and a third male end extends in a directionperpendicular to the first and second male ends. In yet a furtherembodiment, the connector formed from one or more sheets of material asdisclosed herein comprises three male ends disposed 90° from one another(e.g. a corner vertex having x, y, and z-distributed male ends). In suchan embodiment of a connector having x, y and z-distributed male ends,the connector is formed with one or more sheets of material, two or moresheets of material or three sheets of material, wherein the sheets ofmaterial have a plurality of fold lines, wherein folding the multiplesheets along the fold lines to form fingers and interconnecting thefolded sheets configures the fingers to form a plurality of male ends.

In one embodiment of any disclosed aspect, the framework ofinterconnected structural members comprises an adhesive or fastener inaddition to or as an alternative to the tabs and slots disclosed herein.Alternately, the framework can be interconnected using alternativemethods of joining materials include crimping, welding, soldering,brazing, taping, gluing, or cementing.

Fasteners appropriate for use in accordance with the presently disclosedsubject matter can include, but are not limited to, magnets, vacuummeans (such as suction cups), anchors, buckles, clamps (or cramps),clasps, Clekos, clips, flanges, grommets, nails, pegs, pins, retainingrings, rivets, rubber bands (or bands of other materials), snaps,staples, stitches, straps, tacks, threaded fasteners, ties, toggles,velcro brand hook-and-loop strips, and zippers.

As used herein, “adhesive” refers to a composition which demonstratesconnection when applied to another material or composition generally.Adhesive compositions connect to other materials or compositionsgenerally and no particularly selected properties of the other materialor composition are necessary to demonstrate a general tendency toadhere. Adhesives are well-known to those of skill in the art, andinclude, but are not limited to, tape, glue, and double-sided adhesivestrip,

In one variation of any of the disclosed aspects or embodiments, thesheet of material comprises foldable materials, including, but notlimited to paper, plastic, wood, cloth, metal and composite. In anothervariation, the sheet of material comprises paper, plastic or cloth;alternately, the sheet of material comprises paper or plastic. Inanother variation of any of the disclosed aspects or embodiments, thesheet of material comprises plywood, visqueen, fiberboard, containerboard, paper board, cardboard, corrugated paper, corrugated fiberboard,corrugated plastics, non-corrugated plastics, molded pulp, paper pulp,boxboard (cartonboard), folding boxboard, chipboard, Kraft board,laminated board, solid bleached board, solid bleached sulphate, solidunbleached board, lined chipboard, linerboard, and binder's board. Inone variation, the sheet of material is moisture resistant. In anothervariation the sheet of material is coated, such as with awater-resistant material. In yet another variation, the sheet ofmaterial, such as for example, cloth, contains a stiffening agent, suchas wax, starch or a polymer, which confers stiffness to the material,allowing it to be folded and maintain its shape. In yet a furthervariation, the sheet of material is reinforced with a stiffening agentwhich increases the stiffness and/or sturdiness of the material. In onevariation, the sheet of material is single ply; in another variation itis multi-ply. In another variation, the sheet comprises corrugatedmedium, optionally in combination with linerboard.

In an embodiment, structural members disclosed herein can demonstrate ahigh resistance to bending and crushing. In another embodiment, thestructural members disclosed herein can demonstrate increased tensile,compression, and flexure/bend strength.

The following detailed description and appended photographs describe andillustrate various exemplary embodiments of the presently disclosedsubject matter. The description and figures serve to enable one skilledin the art to make and use the presently disclosed subject matter, andare not intended to limit the scope of the presently disclosed subjectmatter in any manner.

FIGS. 1A-1J illustrate various views of an example structural member (orelongate member) 10 and example steps in the assembly thereof inaccordance with embodiments of the presently disclosed subject matter.Particularly, FIGS. 1A and 1B(i) illustrate a perspective view and anend elevational view, respectively, of the structural member 10. In thisexample, the structural member 10 is substantially shaped as a cuboid;however, the structural member 10 may be any other suitable shape. Thestructural member 10 has a substantially square cross-sectional area anda web 12 formed in an interior of the structural member 10. In theillustrated embodiment, a cross section of the web 10 has a generally“X” shape in cross-section, although the cross-section of the web 10 maybe any other suitable shape. For example, the web 10 can be formedhaving a substantially rectangular cross-sectional area. The structuralmember 10 includes a first end 14 and a second end 16. The ends 14 and16 shown in this example are open into the interior of the structuralmember 10, although one or both of the ends 14 and 16 may be closed.

FIG. 1B(ii) is another end elevational view of the elongate structuralmember of FIG. 1 showing an internal web according to an embodiment ofthe present subject matter. FIG. 1B(ii) is a view of the end thatopposes the end shown in FIG. 1B(i). Referring to FIG. 1B(ii), the edges24 and 28 and folds 30A-30J are depicted in an assembled state of thestructural member 10. Further, sections 32A-32J and end section 34 areshown.

FIG. 1C illustrates a top plan view of a sheet of foldable material 20from which the example structural member 10 shown in FIGS. 1A and 1B(i)may be formed according to an embodiment of the presently disclosedsubject matter. Referring to FIG. 1C, the sheet 20 is a one-piececorrugated sheet, although the sheet 20 may include any number of anysuitably shaped corrugated sheets that are attached together in anysuitable manner. It should be understood that the sheet 20 can be formedfrom any suitable type of materials such as, but not limited to,fiberboard, paper board, corrugated plastics, non-corrugated plastics,various foldable materials, and combinations thereof. In this example,the sheet 20 is generally rectangular in shape and defines spaced apartstraight edges 22 and 24 and spaced apart straight edges 26 and 28. Alength of the edges 26 and 28 is substantially equivalent to a desiredend length of the structural member 10 shown in FIG. 1A. Multiple foldlines 30A-30J are formed in the sheet 20. The fold lines 30A-30J extendfrom the edge 22 to the edge 24 and are substantially parallel to theedges 26 and 28. The fold lines 30A-30J define a plurality of sections32A-32J in the sheet 20 which can form sides and the web 12 of thestructural member 10. An end section 34 is defined by the fold line 30Jand the edge 28. As shown in FIG. 1B(i), the end section 34 is adaptedto abut a surface of one of the sections 32 in the structural member 10.In the illustrated embodiment, the end section 34 abuts one of thesections 32 forming the web 12. It should be understood that the endsection 34 can abut one of the sections 32 forming the outer surface ofthe structural member 10. An adhesive (not shown) such as a double sidedadhesive strip or a glue, for example, can be employed to affix the endsection 34 to one of the sections 32.

Tabs 36 and 38 are formed in the sheet 20. A first pair of slots 40 and42 is formed in the sheet 20 to receive the tab 36. A second pair ofslots 44 and 46 is formed in the sheet 20 to receive the tab 38. In theembodiment illustrated in FIG. 1C, the tab 36 is formed in the edge 28and the slots 40 and 42 are formed in the sections 32 of the sheet 20,and the slot 46 is formed in the edge 28 of the sheet 20 and the tab 38and the slot 44 are formed in the sections 32. It should be understoodthat other arrangements of the tabs 36 and 38 and the slots 40, 42, 44,and 46 can be employed. For example, FIG. 1D shows an alternateembodiment of the sheet 20. Structure similar to that illustrated inFIG. 1C includes the same reference numeral and a prime (′) symbol forclarity. In FIG. 1D, the tabs 36′ and 38′ are formed in the edge 28′ ofthe sheet 20′. Further, the slots 40′, 42′, 44′, and 46′ are formed inthe sections 32′ of the sheet 20′.

FIGS. 1E-1J illustrate various perspective views of the sheet 20 shownin FIG. 1C at various steps of folding the sheet 20 to assemble thestructural member 10 shown in FIGS. 1A and 1B(i). Referring to FIG. 1E,the sheet 20 may be folded along the fold lines 30A and 30B in aninitial step, wherein the tab 36 is caused to be received in the slot 40in a subsequent step as shown in FIG. 1F. The sheet 20 may subsequentlybe folded along the fold lines 30D, 30E, and 30F, wherein the tab 36 iscaused to be received in the slot 42 and the tab 38 is caused to bereceived by the slots 44 and 46 to form the web 12 of the structuralmember 10 in another step as shown in FIG. 1G. The sheet 20 may befolded along the fold lines 30F, 30G, 30H, 30I, and 30J, wherein thesections 32G, 32H, 32I, and 32J wrap about the web 12 and form outersurfaces of the structural member 10. The section 34 may abut and may besubstantially affixed to the section 32F to facilitate maintaining thesheet 20 in the folded configuration forming the structural member 10.

In FIGS. 1A-2J, the tabs and slots as shown can be replaced by adhesivesor fasteners consistent with the knowledge of one of skill in the art.Alternately, the structural member 10 can be held in its folded shapeusing other known methods of joining materials include crimping,welding, soldering, brazing, taping, gluing, or cementing.

FIG. 2A is a top plan view of a sheet of material 60 from which aninety-degree connector may be formed according to an embodiment of thepresently disclosed subject matter. The ninety-degree connector may beused, for example, for connecting ends of structural materials to oneanother as described in more detail herein. FIGS. 2B-2D are perspectiveviews of the sheet of material 60 shown in FIG. 2A showing example stepsof folding the sheet of material to assemble a ninety-degree connector50 according to an embodiment of the presently disclosed subject matter.FIG. 2E is a perspective view of the ninety-degree connector 50 formedfrom the sheet of material 60 shown in FIG. 2A according to anembodiment of the presently disclosed subject matter.

Referring now to FIGS. 2A-2I, there is shown a ninety-degree connector50 according to an embodiment of the presently disclosed subject matter.The ninety-degree connector 50 may be employed to affix together ends ofthe structural members 10 together as shown in FIGS. 1A-1J. Theninety-degree connector 50, more clearly shown in FIG. 2E, includes afirst male end 52 and a second male end 54 oriented at about aninety-degree angle in respect of each other. As shown in FIGS. 2G-2I,the first male end 52 is adapted to be received in one of the open ends14 and 16 of the structural member 10 and the second male end 54 isadapted to be received in one of the open ends 14 and 16 of another oneof the structural members 10.

As shown in FIG. 2A, the ninety-degree connector 50 may be assembledfrom a sheet of foldable material 60. In the illustrated embodiment, thesheet 60 is a one-piece corrugated sheet, although it should beunderstood that the sheet 60 can be formed from other foldable materialssuch as fiberboard, paper board, corrugated plastics, non-corrugatedplastics, other foldable materials, or combinations thereof. The sheet60 includes a plurality of first fingers 62A-62E forming the first maleend 52 and a plurality of second fingers 64A-64E forming the second maleend 54. Fold lines 66A-66E may be formed in the sheet 60 to facilitatefolding the sheet 60. Slits 68A and 68B may be formed through the sheet60 to permit the fingers 62D, 62E, 64A, and 64C to be folded out ofplane with finger 64B as shown in FIG. 2B.

In FIGS. 2B-2E, example steps of folding the sheet 60 to form theninety-degree member 50 are shown. Initially, the sheet 60 may be foldedalong the fold lines 66A and 66B, wherein the fingers 62D and 62E arecaused to be orthogonal to the finger 64B. Subsequently, the sheet 60may be folded along the fold line 66C to position the fingers 64A, 64B,and 64C as shown in FIG. 2C. The sheet 60 may subsequently be foldedalong the fold lines 66D and 66E to form the ninety-degree member 50 asshown in FIGS. 2B-2E. Once the ninety-degree member 50 is assembled, themale ends 52 and 54 can be inserted into the open ends 14 and 16 of thestructural members 10, as shown in FIGS. 2F-2I, to connect ends of thestructural members 10 at a ninety-degree angle in respect of each other.It should be understood that an adhesive such as a double sided adhesivestrip, and glue, for example, and a fastener such as a threadedfastener, for example, can be employed to substantially affix the maleends 52 and 54 of the ninety-degree member 50 to the ends of thestructural members 10.

FIG. 3A illustrates a top plan view of a sheet of material 110 fromwhich a T-connector can be assembled according to an embodiment of thepresent subject matter. FIGS. 3B-3C illustrate perspective views of thesheet of material 110 of FIG. 3A showing example steps of folding thesheet of material 110 to form the T-connector according to an embodimentof the presently disclosed subject matter. FIG. 3D-3G are perspectiveviews of a T-connector 100 of FIG. 3C being employed to join togetherthree structural members shown in FIGS. 1A and 1B(i) according to anembodiment of the presently disclosed subject matter. Referring now toFIGS. 3A-3G, the T-connector 100 is employed to join together ends ofthree structural members 10 as shown in FIGS. 1A-1J. The T-connector100, more clearly shown in FIG. 3C, includes a first male end 102, asecond male end 104, and a third male end 106 oriented to form agenerally T-shape for the T-connector 100. The male ends 102, 104, and106 are shaped and sized to be received in the open ends 14 and 16 ofthe structural members 10, wherein the T-connector 100 is employed toaffix together three of the structural members 10 as shown in FIGS.3F-3G.

As shown in FIG. 3A, the T-connector 100 may be formed from a sheet offoldable material 110. In the illustrated embodiment, the sheet 110 is aone-piece corrugated sheet, although it should be understood that thesheet 110 can be formed from other foldable materials such as, but notlimited to, fiberboard, paper board, corrugated plastics, non-corrugatedplastics, and other foldable materials, for example. The sheet 110includes a plurality of first fingers 112A, 112B, and 112C forming thefirst male end 102, a plurality of second fingers 114A, 114B, and 114Cforming the second male end 104, and a plurality of third fingers 116Aand 116B forming the third male end 106. Fold lines 118 and 120 can beformed in the sheet 110 to facilitate folding the sheet 110 to form theT-connector 100.

In FIGS. 3B and 3C, example steps of folding the sheet 110 to form theninety-degree member 100 are shown. In an initial step, the sheet 110 isfolded along the fold lines 118 and 120, wherein the fingers 116A and116B are caused to be orthogonal to the fingers 112B and 114B and formthe generally T-shaped T-connector 100. Once the T-connector 100 isformed, the male ends 102, 104, and 106 can be inserted into the openends 14 and 16 of the structural members 10, as shown in FIGS. 3D-3G. Itshould be understood that an adhesive such as, but not limited to, adouble sided adhesive strip and a glue, for example, and a fastener suchas a threaded fastener, for example, can be employed to substantiallysecure the male ends 102, 104, and 106 of the T-connector 100 to thestructural members 10.

FIG. 4A illustrates a top plan view of sheets of material 160, 180, and200 from which a corner connector may be assembled according to anembodiment of the presently disclosed subject matter. FIGS. 4B-4Jillustrate perspective views of the sheets of material 160, 180, and 200of FIG. 4A showing example steps of interconnecting and folding thesheets of material 160, 180, and 200 of FIG. 4A to assemble a cornerconnector according to an embodiment of the presently disclosed subjectmatter. FIGS. 4K-4N are perspective views of the corner connector ofFIG. 4I being employed to join together three of the elongate structuralmembers of FIGS. 1A and 1B according to an embodiment of the presentlydisclosed subject matter. Referring now to FIGS. 4A-4N, there is shown acorner connector 150 according to an embodiment of the presentlydisclosed subject matter. The corner connector 150 is employed to jointogether three of the structural members 10 illustrated in FIGS. 1A-1J.The corner connector 150, more clearly shown in FIG. 4I, includes afirst male end 152, a second male end 154, and a third male end 156oriented to assemble a three-way corner shape to the corner connector150. The male ends 152, 154, and 156 are adapted to be received in theopen ends 14 and 16 of the structural members 10, wherein the cornerconnector 150 is employed to join together three of the structuralmembers 10 as shown in FIGS. 4L-4N.

As shown in FIG. 4A, the corner connector 150 is formed from a firstsheet 160, a second sheet 180, and a third sheet 200. In the illustratedembodiment, the sheets 160, 180, and 200 are a one-piece corrugatedsheet, although it should be understood that the sheets 160, 180, and200 can be formed from other foldable materials such as, but not limitedto, fiberboard, paper board, corrugated plastics, non-corrugatedplastics, other foldable materials, or combinations thereof, forexample.

The sheet 160 includes a plurality of fingers 162, 164A, 164B, and 166.Fold lines 168 and 170 are formed in the sheet 160 to facilitate foldingthe sheet 160. A slot 172 is formed in the sheet 160 adjacent a base ofthe finger 166. The sheet 180 includes a plurality of fingers 182, 184,186A, and 186B. Fold lines 188 and 190 are formed in the sheet 180 tofacilitate folding the sheet 180. A slot 192 is formed in the sheet 180adjacent a base of the finger 184 adapted to cooperate with the slot 172of the sheet 160 to join together the sheet 160 and the sheet 180 asshown in FIG. 4B. The sheet 200 includes a plurality of fingers 202A,202B, 204A, 204B, 206A, and 206B. Fold lines 208 and 210 are formed inthe sheet 200 to facilitate folding the sheet 200. In the cornerconnector 150, the fingers 162, 182, 202A, and 202B form the first maleend 152; the fingers 164A, 164B, 184, 204A, and 204B form the secondmale end 154; and the fingers 166, 186A, 186B, 206A, and 206B form thethird male end 156.

Referring now to FIGS. 4C-4J, example steps of interconnecting andfolding the sheets 160, 180, and 200 to form the corner connector 150are shown. Referring particularly to FIGS. 4C-4F, the finger 162 of thesheet 160 is inserted into the end 14 of the structural member 10. Thefinger 182 of the sheet 180 is also inserted into the end 14 of thestructural member 10, wherein the slots 172 and 182 of the sheets 160and 180, respectively, cooperate to interconnect the sheets 160 and 180.As shown in FIG. 4H, the fingers 164A and 164B are folded along the foldlines 168 and 170, respectively, toward the finger 184 to form a portionof the second male end 154 of the corner connector 150. In a similarmanner, the fingers 186A and 186B are folded along the fold lines 190and 188, respectively, toward the finger 166 to form a portion of thethird male end 156 of the corner connector 150. The sheet 200 is foldedalong the fold lines 208 and 210 as shown in FIG. 4G.

Now referring to FIGS. 4I-4J, the fingers 202A and 202B are insertedinto the end 14 of the structural member 10, wherein the fingers 162,182, 202A, and 202B form the first male end 152 of the corner connector150. Further, the fingers 204A and 204B are substantially aligned withthe fingers 164A and 164B, respectively, and together with the finger184, form the second male end 154 of the corner connector 150.Similarly, the fingers 206A and 206B are substantially aligned with thefingers 186A and 186B, respectively, and together with the finger 166,form the third male end 156 of the corner connector 150. Once the cornerconnector 150 is formed as shown in FIG. 4I, the male ends 154 and 156can be inserted into the open ends 14 and 16 of the structural members10, as shown in FIGS. 4K-4N. It should be understood that an adhesivesuch as, but not limited to, a double sided adhesive strip and a glue,for example, and a fastener such as a threaded fastener, for example,can be employed to substantially secure the male ends 152, 154, and 156of the corner connector 150 to the structural members 10.

It should be understood that a plurality of the structural members 10,the ninety-degree connectors 50, the T-connectors 100, and the cornerconnectors 150 can be used to construct a desired structure or frameworkfor a variety of items such as a chair, a table, a cot, a shelf, ashipping pallet, a shipping crate, a shelter, and the like, for example.It should also be understood that one or more panels can be coupled tothe structural members 10 and the connectors 50, 100, and 150 to coverat least a portion of the structure or the framework formed from thestructural members 10 and the connectors 50, 100, and 150.

The sheets 20, 60, 110, 160, 180, and 200 can be shipped from amanufacturing location to an end user as flat sheet material to minimizea cost of shipping. The end user can fold the sheets 20, 60, 110, 160,180, and 200 to form the respective structural members 10 and theconnectors 50, 100, and 150. Once formed, the structural members 10 andthe connectors 50, 100, and 150 can be joined together to assemble orform the desired structure or framework.

FIG. 5 is a top plan view of a sheet of material 80 from which a trussconnector may be formed according to an embodiment of the presentsubject matter. Referring to FIG. 5, the sheet of material 80 definesseveral fold lines 82, 84, and 86 and fingers 88, 90, 92, 94, 96, and98. In a first step to form the truss connector, the sheet of material80 can be folded along fold lines 84 and 86 such that the portion of thesheet of material 80 including fingers 88 and 90 is substantiallyparallel with the portion of the sheet of material 80 including fingers96 and 98. Further, the portions including fingers 88, 90, 96, and 98are positioned to be substantially perpendicular to the portionincluding fingers 92 and 94. In a subsequent and final step forassembling the truss connector, the sheet of material 80 can be foldedalong fold line 82 such that edges 100 and 102 touch and such that edges104 and 106 touch. Touching edge pairs 100/102 and 104/106 canoptionally be affixed using an adhesive means as disclosed herein. As aresult, fingers 90, 94, and 98 are substantially aligned to form a firstmale end to be received by a structural member; further, fingers 88, 92,and 96 are substantially aligned to form a second male end to bereceived by another structural member. The first male end (formed fromfingers 90, 94, and 98) points in a direction that is greater than 90°apart from the direction of the second male end (formed from fingers 88,92, and 96). Such a sheet can also be configured to provide more fingersfor each male end, or double-thickness fingers, thereby reinforcing theintegrity of the male end. Alternately, such a truss connector can beformed from more than one sheet of material, consistent with thedisclosure herein.

Those of skill in the art will appreciate that some of the elements inthe figures are illustrated for simplicity and clarity and have notnecessarily been drawn to scale. For example, the dimensions and/orrelative positioning of some of the elements in the figures may beexaggerated relative to other elements to help to improve understandingof various embodiments of the presently disclosed subject matter. Also,common but well-understood elements that are useful or necessary in acommercially feasible embodiment are often not depicted in order tofacilitate a less obstructed view of these various embodiments of thepresently disclosed subject matter. It will further be appreciated thatcertain actions and/or steps may be described or depicted in aparticular order of occurrence while those skilled in the art willunderstand that such specificity with respect to sequence is notactually required. It will also be understood that the terms andexpressions used herein have the ordinary technical meaning as isaccorded to such terms and expressions by persons skilled in thetechnical field as set forth above except where different specificmeanings have otherwise been set forth herein.

Features from one embodiment or aspect may be combined with featuresfrom any other embodiment or aspect in any appropriate combination. Forexample, any individual or collective features of method aspects orembodiments may be applied to apparatus, system, product, or componentaspects of embodiments and vice versa.

While the embodiments have been described in connection with thepreferred embodiments of the various figures, it is to be understoodthat other similar embodiments may be used or modifications andadditions may be made to the described embodiment for performing thesame function without deviating therefrom. Therefore, the disclosedembodiments should not be limited to any single embodiment, but rathershould be construed in breadth and scope in accordance with the appendedclaims.

What is claimed:
 1. A sheet of material defining at least one tab, apair of slots, and a plurality of fold lines, wherein the fold lines arespaced such that folding the sheet along the fold lines places the slotsin substantial alignment for receiving the at least one tab such that astructural member having a web formed in an interior thereof is formed.2. The sheet of material of claim 1 being made of one of paper, plastic,wood, cloth, metal, and composite.
 3. The sheet of material of claim 1,wherein the web is X shape in cross-section.
 4. The sheet of material ofclaim 1, wherein the sheet comprises an end, and wherein the at leastone tab is defined at the end.
 5. The sheet of material of claim 1,wherein the at least one tab is defined along one of the fold lines. 6.A framework of interconnected structural members formed from sheets ofmaterial, the framework comprising: an elongate member having a firstend and a second end and a web formed in an interior thereof, whereinthe elongate member is formed from a first sheet of material defining atleast one first attachment portion, at least one second attachmentportion, and a plurality of fold lines, wherein the fold lines arespaced such that folding the sheet along the fold lines places the atleast one second attachment portion in substantial alignment forattachment to the at least one first attachment portion such that theelongate member having the web formed in the interior is formed; and aconnector including at least a first male end and a second male end,wherein the male ends are received in one of the first end and thesecond end of the elongate member to selectively join together aplurality of the elongate members, wherein the connector is formed fromat least one second sheet of material defining a plurality of fingers,wherein the at least one second sheet defines a plurality of fold lines,wherein folding the at least one second sheet along the fold linesconfigures the fingers to form the first male end and the second maleend of the connector.
 7. The framework of claim 6, wherein the firstsheet of material and the second sheet of material are eachindependently made of one of paper, plastic, wood, cloth, metal, andcomposite.
 8. The framework of claim 6, wherein the web is X shape incross-section.
 9. The framework of claim 6, wherein the at least onefirst attachment portion defines a tab, wherein the at least one secondattachment portion defines a slot, and wherein the slot is configuredfor receipt of the tab for attachment.
 10. The framework of claim 6,wherein the at least one first attachment portion and the at least onesecond attachment portion are configured to be adhered to each other.11. The framework of claim 6, wherein the first male end and the secondmale end of the connector are configured to each engage an end of one ofthe elongate members such that the elongate members are perpendicular toone other.
 12. A sheet of material for forming a connector to assembletogether a plurality of structural members, wherein the sheet defines aplurality of fingers and a plurality of fold lines, wherein folding thesheet along the fold lines configures the fingers to form a plurality ofmale ends for receipt in an opening of a structural member toselectively assemble together a plurality of the structural members. 13.The sheet of material of claim 12 being made of one of paper, plastic,wood, cloth, metal, and composite.
 14. The sheet of material of claim12, wherein the male ends extend in directions that are perpendicular toone another.
 15. The sheet of material of claim 12, wherein theplurality of fingers include a first pair of fingers and a second pairof fingers positioned on opposing sides of one of the fold lines,wherein the first and second pair of fingers are positioned such thatfolding along the fold lines forms: a first male end from the first pairof fingers, wherein the fingers are substantially parallel and adjacentto one another, and a second male end from the second pair of fingers,wherein the fingers are substantially parallel and adjacent to oneanother.
 16. The sheet of material of claim 12, wherein the first maleend extends in an opposite direction from the second male end.
 17. Thesheet of material of claim 16, further comprising a third male endwherein the third male end extends in a direction substantiallyperpendicular to the direction of the first and second male ends. 18.The sheet of material of claim 12, wherein the male ends are configuredto each engage an end of one of the structural members such that thestructural members are between about 90° and about 180° apart.
 19. Thesheet material of claim 18, wherein two male ends are about 135° apart.20. A framework of claim 6 wherein said framework is one of a chair, atable, a desk, a trunk, a bench, a stool, a cot, a shelf, a pallet, acrate, a platform, a raised floor, a display, and a shelter.